Exterior opaque hidden frame wall unit

ABSTRACT

Exterior opaque hidden frame wall units and systems combining facing plates and composite insulated panels in a pressure-equalized Airloop system, permitting an opaque hidden frame wall unit without the need for intermediate stiffeners for resisting wind load, without exterior aesthetic problems associated with composite insulated panels, without a separate interior wall, and without interior condensation problems. Also provided are exterior opaque hidden frame Airloop wall units and systems with the air seal being isolated from the water seal on an offset vertical plane and away from the interior surface of the facing plate.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional PatentApplication No. 61/809,022, filed Apr. 5, 2013, and which is herebyincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

This invention is related to the building envelope system designapplicable to an exterior wall design such as a curtain wall system or awindow wall system.

An exterior wall is formed by multiple wall units joined and sealedbetween two adjacent wall units in both horizontal and verticaldirections. The major functions of an exterior wall include theaesthetic design provided by the project architect and the interiorenvironmental protection design provided by the exterior wall systemdesigner or supplier. It is well recognized in the industry that windload resistance and water-tightness performance are the two mostimportant functions in the interior environmental protection design. Inopaque areas such as spandrel and column areas, the required functionsof the completed wall include maintaining aesthetic performance in theexterior environment, providing thermal insulation, and providing afinished interior wall. A popular aesthetic design option for the opaquearea is a hidden frame wall unit. There are two major types of opaquehidden frame wall units in today's market.

The first type of opaque hidden frame wall unit is a plate systemconsisting of a flat facing plate such as aluminum plate, ACM (aluminumcomposite material), stone, or glass and a perimeter frame to supportthe plate. The facing plate is structurally tied to the perimeter frameby a connecting means such as adhesive tape, structural siliconecaulking, or welded studs, etc. for wind load resistance and sealed inbetween to provide water-tightness performance. In a conventional wallunit of this type, the connecting location is designed for sealing bothair and water requiring a perfect seal. Because no seal can be trulyperfect, such wall units are prone to water leakage problems.

In an Airloop System (U.S. Pat. No. 5,598,671, which is incorporated byreference), the water leakage problem is solved by creating a perimeterAirloop to isolate the air seal from the water seal. An Airloop Systemseparates the air seal from the water seal, allowing for pressureequalization between the exterior air and the cavities in the perimeterframe. The equalized air pressure prevents water infiltration into thewall unit. However, the pressure equalization process takes a shortperiod of time, and some incidental water infiltration may occur duringthat time. The infiltrated water will drain out of an Airloop system viaair holes in the perimeter frame. In a hidden frame Airloop system, thewater seal and the air seal are on the same vertical plane. Because ofthis, and the incidental water infiltration that may occur during theshort time required for pressure equalization, the tolerable degree ofseal imperfection in a hidden frame Airloop system is not as good asthat for an exposed frame Airloop system (U.S. Pat. No. 7,134,247, whichis incorporated by reference). Separation of the water seal and the airseal into different vertical planes in a hidden frame Airloop system,therefore, is desirable to enhance performance during the time requiredfor pressure equalization.

In addition, quality control for the execution of the connecting meansis critical to ensure structural safety against the facing plate beingblown away by wind. Another structural problem with hidden frame wallunits is that the thin facing plate is flexible and intermediatestiffeners are often required, creating a significant cost increase. Tocomplete the wall system, thermal insulation with a vapor barrier isinstalled behind the exterior wall unit and a separate interior wall isinstalled to create the interior aesthetic design. Since the interiorsurface of the facing plate is in the interior air zone, in coldregions, quality control on the installation of the vapor barrier iscritical for preventing interior water condensation on the interiorsurface of the facing plate. Interior water condensation on the opaquewall unit often leads to latent discovery of the serious problems of wetinsulation and connection corrosion.

The second type of opaque hidden frame wall unit is a composite panelsystem consisting of two thin structural skins with structuralinsulating core sandwiched in between. The most popular product of thissystem is known as composite foam panel. The advantage of this system isthe significant cost reduction due to the following factors: (1)elimination of perimeter frame due to the combination of structural andthermal insulating functions; (2) elimination of the separate interiorwall if the interior panel surface is used as the finished wall surface.However, the system is prone to exterior aesthetic problems known asthermal bowing, thermal blistering and thermal rippling. Such systemsalso are prone to water leakage problems at the interface locations suchas window perimeters.

BRIEF SUMMARY OF THE INVENTION

Preferred embodiments of the invention provide an opaque hidden framewall unit without the need for intermediate stiffeners for resistingwind load. Preferred embodiments also provide an opaque Airloop hiddenframe wall unit with the air seal being isolated from the water seal onan offset vertical plane and away from the interior surface of thefacing plate. Further, preferred embodiments provide an opaque Airloophidden frame wall unit without exterior aesthetic problems and without aseparate interior wall. Finally, preferred embodiments of the inventionprovide an opaque Airloop hidden frame wall unit without interior watercondensation problems.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the front view of a typical exterior wall unit of thepresent invention.

FIG. 2A shows one embodiment of the fragmental head and sill details ofthe cross-section taken along Line 2-2 of FIG. 1.

FIG. 2B shows an alternate embodiment of the fragmental head and silldetails of the cross-section taken along Line 2-2 of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows the front view of an Airloop wall unit 10 of an embodimenthaving a facing plate 11 and four perimeter frame members 12, 13, 14,and 15 hidden behind the facing plate 11. The four members 12, 13, 14,and 15 have compatible cavity profiles such that an inner Airloop isformed when the frames are miter-match connected at the four corners 16,17, 18, and 19. Member 12 is the head member which is situated at theerected top position of unit 10. Member 13 is the sill member which issituated at the erected bottom position of unit 10. Members 14 and 15are the jamb members which are situated at the erected sides of unit 10.As shown for illustration purposes, the unit 10 shown in the embodimentof FIG. 1 is a rectangular unit with four perimeter frame members. Inother embodiments, the wall unit may be formed into other shapes with atleast one perimeter member. For example, a single perimeter member canbe formed into a rounded shape, or multiple straight or curved perimetermembers miter-matched at all intersection points can be formed into anyother shape. The Airloop wall unit 10 embodiment shown in FIG. 1 may beshop assembled in the following sequential steps: (1) provide structuralconnecting means at each miter-matched corner to form an empty frameconsisting of the four members 12, 13, 14, and 15; (2) glaze in thefacing plate 11 and a back-up composite insulated panel (shown on FIG.2A or 2B).

FIG. 2A shows the fragmental head details 20 and the fragmental silldetails 30 on the cross-section taken along Line 2-2 of FIG. 1 for apreferred Airloop hidden frame plate system. The glazing processinvolves the following sequential steps: (1) install the air seal 22around the frame; (2) secure the composite insulated panel 21 intoposition on at least one of the frame members using a glazing bead 52and spaced apart segments of a glazing material 23 to create at leastone air gap between two segments of the glazing material 23; (3) securethe facing plate 11 to each of the frame members using an adhesive tape24. In other embodiments, any other structural panel capable ofresisting wind load may be used in place of the preferred compositeinsulated panel 21. In the preferred embodiment shown in FIG. 2A, theglazing material for securing the panel 21 into position is a wedgegasket 23. Alternative glazing materials, such as caulking or plasticshims, may also be used. Further, alternative structural agents apparentto those of skill in the art, such as structural silicone caulking,welded studs, or anchor bolts, may be used to secure the facing plate tothe frame members.

When the composite insulated panel 21 is glazed into position, the innerAirloop 27 is formed. The most commonly used material for the framemembers is aluminum extrusion. Popular facing plate 11 materials includealuminum plate, ACM (aluminum composite material), single pane spandrelglass, and finished natural stone. Shown as a preferred system for coldclimate regions, a thermal break material 25 is used on all framemembers. At least one air hole is drilled through sill member 13 toconnect the inner Airloop 27 to the air space below sill member 13. Inthe preferred embodiment shown in FIG. 2A, the at least one air hole 26is drilled through the thermal break material to connect the innerAirloop 27 to the air space below the sill member 13.

The erection procedures include the following steps: (1) secure theAirloop unit to the supporting mullions (not shown); (2) install therain screen member 28 and the water seal member 29; (3) start erectingthe unit above by causing the sill member 13 of the unit above to beinterlocked with the head member 12, forming the outer Airloop with theinter-connected joint cavities. In this arrangement, the space 31between the facing plate 11 and the composite insulated panel 21 ispressure-equalized due to the fact that the air gaps between twoadjacent segments of the gasket 23 are used to connect the space 31 tothe inner Airloop. Therefore, the adhesive tape 24 is acting as astructural agent connecting the facing plate 11 to the frame members andalso acting as a water seal since the space 31 is pressure-equalized.Since the space 31 behind the facing plate is pressure-equalized to theexterior air, the wind load on the facing plate 11 is greatly minimized.The facing plate 11 will experience greater wind load during thepressure-equalization process, which lasts for only a short period oftime; therefore, the need for intermediate plate stiffeners iseliminated.

As shown, the air seal 22 is far away from the adhesive tape 24 actingas the water seal and also far away from the interior surface of thefacing plate 11, enhancing water-tightness performance during the timeneeded for the pressure equalization process.

The gasket segments 23 serve as a glazing material to secure the panel21 for resisting wind load. The panel 21 is used for resisting the windload and providing thermal insulation. The smooth interior skin of panel21 may be used as the finished interior wall surface, while the exteriorskin of panel 21 is hidden by the facing plate 11. The interior skin ofpanel 21 is exposed to the interior air and is isolated from theexterior cold skin by the insulating panel core 32, preventing thetemperature of the interior skin of panel 21 from reaching the dew pointand consequently preventing interior water condensation.

FIG. 2B shows another preferred embodiment for the fragmental head 40details and the fragmental sill 50 details on the cross-section takenalong Line 2-2 of FIG. 1 for an Airloop hidden frame plate system. Theglazing process for this embodiment may involve the following sequentialsteps: (1) secure the composite insulated panel 21 into position using aglazing bead 52 a and continuous glazing material 23 a on all framemembers; (2) secure the facing plate 11 to each of the frame membersusing an adhesive tape 24. When the composite insulated panel 21 isglazed into position, the inner Airloop 27 is formed. Shown as apreferred system for cold climate regions, a thermal-break material 25is used on all frame members. As shown, air holes 26 are drilled throughthe thermal break material connecting the inner Airloop 27 to the airspace below the sill member 13 a. In the preferred embodiment shown inFIG. 2B, the continuous gasket 23 a is used as the glazing material forsecuring panel 21 in position and also as the air seal. An additionalair seal 41 is required between the glazing bead 52 a and the framemember 12 a or 13 a. The contacting surface 42 between the exterior skinof panel 21 and the frame member 12 a or 13 a is unsealed to allowpressure equalization air to come from the inner Airloop 27 into thespace 31. To reduce the time lag for pressure equalization of space 31,a profile with valleys may be rolled into the exterior skin of panel 21such that air flow can freely go through the cavities created by thevalleys. Other texture variations applied to the exterior skin of panel21 may also be utilized to increase airflow between the exterior skin ofpanel 21 and the frame member 12 a or 13 a. The erection procedures andthe functional explanations are the same as explained for the embodimentshown in FIG. 2A.

Even though a typical Airloop hidden frame wall unit is used inillustrating the present invention, some of the design features can beused in other conventional systems to improve their functionalperformances.

Nothing in the above description is meant to limit the present inventionto any specific materials, geometry, or orientation of elements. Manymodifications are contemplated within the scope of the present inventionand will be apparent to those skilled in the art. The embodimentsdescribed herein were presented by way of example only and should not beused to limit the scope of the invention.

The invention claimed is:
 1. A wall unit, comprising an exterior facingplate, a frame member, a structural agent securing said exterior facingplate to the exterior of said frame member, a structural panel securedto said frame member by a glazing bead and a glazing material, whereinsaid exterior facing plate conceals said structural panel from view onan exterior side of said wall unit, an air seal sealing air on aninterior side of said wall unit from air in an air space between saidframe member and said structural panel, wherein said air space betweensaid frame member and said structural panel is connected with an airspace between said structural panel and said facing plate, and whereinsaid air space between said frame member and said structural panel isconnected and pressure equalized with air on the exterior side of saidwall unit.
 2. The wall unit of claim 1, wherein said air seal isdisposed in a different vertical plane than said structural agentsecuring said exterior facing plate.
 3. The wall unit of claim 1,wherein said structural agent is an adhesive tape.
 4. The wall unit ofclaim 1, wherein said structural panel is a composite insulated panel.5. The wall unit of claim 4, wherein one side of said compositeinsulated panel is exposed to a building interior.
 6. The wall unit ofclaim 1, wherein said glazing material is a wedge gasket.
 7. The wallunit of claim 6, wherein said glazing bead and said wedge gasket are onan exterior side of said structural panel.
 8. The wall unit of claim 6,wherein said glazing bead and said wedge gasket are on an interior sideof said structural panel, wherein an exterior side of said structuralpanel contacts said frame member, and wherein an air-tight seal is notcreated between said exterior side of said structural panel and saidframe member.
 9. An exterior wall system comprising a plurality of thewall units of claim 1.